MEX (Metal)

Material Extrusion / Metal FFF

ISO/ASTM Material Extrusion applied to metal. Filaments or rods of metal-polymer composite (MIM feedstock) are extruded, then debound and sintered. Often called Metal FFF.

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Operating Principle & Process Flow

Operating Principle: A filament of metal-polymer composite (MIM feedstock) is melted and extruded. After printing, a "green part" is debound and sintered.

Process Flow: Filament extrusion (printing) → Debinding (chemical or thermal) → Sintering (powder particle fusion in furnace).

Technical Specifications

Energy Source: Heat in the extrusion nozzle (to melt the binder, not the metal) + high-temperature furnace.
Feedstock / Material Feed: Wire/filament of bound metal powder.
Typical Part Size: Small to medium.
Build Rate: Low.
Accuracy: Low to medium (significant shrinkage in furnace).
Surface Quality: Moderate (FFF layer lines often visible after sintering).

Applications & Materials

Typical Materials: Stainless steels (17-4PH, 316L), tool steels (H13), copper.

Typical Applications: Tooling prototypes, jigs & fixtures, fit-and-form parts.

Industries: Tooling, education, prototyping.

Advantages

Very low equipment cost; extremely safe office operation (no loose metal powder, no laser); very easy to operate.

Disadvantages / Limitations

Disadvantages: Significant residual porosity; high shrinkage (~20%) makes dimensional accuracy difficult; lower strength than PBF.

Limitations: Parts rarely suitable for safety-critical end-use under high dynamic load.

Economics

Very economical for occasional printing of individual fixtures or prototypes without major infrastructure investment.

ISO/ASTM Classification

Uses FDM mechanics, but metallurgically similar to Metal Binder Jetting (both require sintering).

Machine Mediation

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Metal Additive Manufacturing

Orientation for Custom Component Requirements

Explore the capabilities of modern metal additive manufacturing, compatible alloys, and post-processing workflows for your specific component project.